Transaction and id cards having selected texture and coloring

ABSTRACT

Cards made in accordance with the invention include a specially treated thin decorative layer attached to a thick core layer of metal or ceramic material, where the thin decorative layer is designed to provide selected color(s) and/or selected texture(s) to a surface of the metal cards. Decorative layers for use in practicing the invention include: (a) an anodized metal layer; or (b) a layer of material derived from plant or animal matter (e.g., wood, leather); or (c) an assortment of aggregate binder material (e.g., cement, mortar, epoxies) mixed with laser reactive materials (e.g., finely divided carbon); or (d) a ceramic layer; and (e) a layer of crystal fabric material. The cards may be dual interface smart cards which can be read in a contactless manner and/or via contacts.

This application is a Divisional Application of U.S. application Ser.No. 14/718,596, filed May 21, 2015, which claims priority based on aprovisional application titled TRANSACTION AND ID CARDS WITH CONTROLLEDCOLORING bearing Ser. No. 62/001,706 filed May 22, 2014 whose teachingsare incorporated herein by reference. This application also claimspriority based on a provisional application titled CERAMIC TRANSACTIONALAND IDENTIFICATION CARDS WITH CONTROLLED COLORING bearing Ser. No.62/074,305 filed Nov. 3, 2014 whose teachings are incorporated herein byreference.

BACKGROUND OF THE INVENTION

This invention relates to the manufacture of metal cards having variedcoloring and texture. In particular, the present invention relates toapparatus and methods for producing transactional and ID cards, or anylike document, having a metal layer where the card can be made to have avariety of colors and textures. This invention also relates to cardshaving a core layer of ceramic material and to metal cards withdecorative ceramic layers.

It has become desirable to provide metal or ceramic cards for the highend market to impart a sense of wealth and distinction to the cardholder. It is also desirable to provide metal cards with differentcolors and textures to further enhance eye and touch appeal and/orprovide a degree of personalization.

It is known to use physical vapor deposition (PVD) to color metaltransaction cards, but PVD is limited in its color range and is alsorelatively expensive. PVD is also highly dependent upon the substrateupon which it is being deposited. PVD is a vacuum process with high heatand batch operation that is expensive requiring individual racking andturning of parts for even distribution of color. It also subjects themetal to high temperature which can shrink and warp the metal

In some metal cards, printed PVC layers or other polymers are used todecorate the outside of cards. The use of these polymeric layers hasundesirable traits such as minimum print thickness, loss of weight inthe metal card due to polymeric thickness, and challenges of laminationof dissimilar materials. Use of different thicknesses and compounds canalso cause the parts to warp or bow due to uneven shrinkage duringplaten lamination.

It is an object of this invention to overcome these and other problemsand to enable the manufacture of metal cards and/or ceramic cards havinga wide range of colors and textures.

SUMMARY OF THE INVENTION

Cards made in accordance with the invention include a specially treatedthin decorative layer attached to either side, or both sides, of a thickcore layer of metal, ceramic coated metal or polymer, or solid ceramicmaterial, where the thin decorative layer is designed to provideselected color(s) and/or selected texture(s) to a surface of the cards.Decorative layers for use in practicing the invention include: (a) ananodized metal layer; or (b) a layer of material derived from plant oranimal matter (e.g., wood, leather); or (c) an assortment of aggregatebinder material (e.g., cement, mortar, epoxies) mixed with laserreactive materials (e.g., finely divided carbon); or (d) a ceramiclayer; and (e) a layer of crystal fabric material. The cards may be dualinterface smart cards which can be read in a contactless manner and/orvia contacts.

The manufacture of metal cards in accordance with the invention includesthe preparation and treatment of a generally thin decorative layer andattaching the decorative layer to a thick metal substrate; where thethin decorative layer is designed to provide selected color(s) and/orselected texture(s) primarily to the front surface of the metal cardsbut also to the back of the cards.

Where the thin decorative layer is an anodized metal layer, the metallayer is prepared and treated to have a selected color for imparting thecoloring to the card. Adding color (colorizing) to metal layers byanodizing is preferable to the PVD process for several reasons.Anodizing is an electrochemical process that converts the metal surfaceinto a decorative, durable, corrosion-resistant. anodic oxide finish.Thus, coloring a metal by anodizing is highly desirable. Aluminum isideally suited to anodizing. However, other nonferrous metals, such asmagnesium, titanium, zinc, niobium, tantalum, or any other metal whichcan be anodized, can be used to practice the invention.

As for aluminum films, for example, the anodic oxide structureoriginates from the aluminum substrate and is composed entirely ofaluminum oxide. This aluminum oxide is not applied to the surface likepaint or plating, but is fully integrated with the underlying aluminumsubstrate, so it cannot chip or peel. It has a highly ordered, porousstructure that allows for secondary processes such as coloring andsealing.

Anodizing may be accomplished by immersing the aluminum into an acidelectrolyte bath (tank) and passing an electric current through themedium. A cathode is mounted to the inside of the anodizing tank; thealuminum acts as an anode, so that oxygen ions are released from theelectrolyte to combine with the aluminum atoms at the surface of thepart being anodized. Anodizing is, therefore, a matter of highlycontrolled oxidation—the enhancement of a naturally occurringphenomenon. Color may be introduced by running the anodized foil througha dye bath of the appropriate (desired) color and then a sealer bath.

Using a colorized anodic layer upon a metal layer provides moreflexibility and cost savings. Use of printed anodic material to replacepolymeric materials overcomes these challenges since the metal is denserthan the polymer and does not have the minimum print thicknesslimitations. This composition and method may be used on all transactionand ID card types including contactless, contact, and dual interfacesmart cards.

In accordance with the invention, the color and/or texture of ananodized layer may be further modified by: (a) dying the anodized layera single color or multiple colors, or (b) by printed graphics throughtechniques such as screen printing, sublimation printing, or any digitalprint system. The anodized metal layer may be further modified throughtechniques such as laser engraving, mechanical engraving, die cutting,or embossing. The anodized metal layer may be used on the card as a fullfaced material (i.e., extending the full length and width of the card),as a patch, a stripe, or other decorative design. The anodized metal maybe laser marked, or otherwise engraved or marked such that base or noblemetals may be electroplated to the anodized surface in a selectivepattern or flood coal

In accordance with one aspect of the invention, the imparting of colorto multilayered metal cards is achieved using at least one anodizedcolored metal layer and selectively modifying the other layers, whichmay or may not be colored, to provide a desired artistic and/orfunctional effect.

Where the decorative layer is a layer of material derived from plantmatter (e.g., wood) special care must be taken to treat the decorativelayer to preserve the original (unique) pattern and texture before andduring the attachment of the decorative layer to a metal substrate.Texture as used herein refers to the visual and especially tactilequality of a surface. This includes the feel, touch, appearance andgraininess of the surface.

Likewise, where the decorative layer is a layer of material derived fromanimal matter (e.g., leather) special processes were developed to treatthe decorative layer to preserve the original (unique) pattern andtexture before and during the attachment of the decorative layer to ametal substrate.

Also, where the decorative layer is a layer of material derived from anassortment of aggregate binder material (e.g., cement, mortar, epoxies)mixed with laser reactive materials (e.g., finely divided carbon)special arrangements are made to produce cards with top surfaces havingdesired color and texture.

Also, various ceramic materials having selected texture and color may beused to form decorative layers attached to a metal substrate.

Thus, the thin decorative layer may be a veneer layer of texturedmaterials which may be natural and/or of a non-metallic nature which areprepared and treated to provide unique and/or selected texture to thecard surface.

Cards embodying the invention include a thin decorative layer and athick core layer of metal, ceramic coated metal, ceramic coated polymer,or solid ceramic material. In addition, the cards may include a numberof different polymeric layers. Still further, metal cards embodying theinvention may include an integrated circuit chip and antennas forenabling RF transmission of signals between the cards and a card reader.These cards are “smart” cards capable of also functioning as contactcards, and/or dual interface (contact and/or contactless).

Still further, cards embodying the invention may include a pocket formedin the top surface of the card to enable the placement therein of one ormore of the decorative layers.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings, which are not drawn to scale, likereference characters denote like components; and

FIG. 1 is a cross sectional diagram of colored layers combined to form ametal card with controlled coloring in accordance with the invention;

FIG. 1A is a cross sectional diagram illustrating the removal ofportions of the top layer of the card shown in FIG. 1 displayingdifferent colors;

FIG. 1B is a cross sectional diagram illustrating the removal ofportions of the two top layers of the card shown in FIG. 1 displayingstill more colors;

FIG. 2 is a cross sectional diagram of selected layers used to form acard having metal and polymeric layers embodying the invention;

FIG. 3 is a cross sectional diagram of a dual interface smart cardhaving colored layers and a metal layer and polymeric layers embodyingthe invention;

FIG. 4 is an exploded view of the layers and components of a card of thetype shown in FIG. 3 (except that the adhesive layers have beenomitted);

FIG. 5 is a cross sectional diagram of a card which includes anembossable layer of thermally set polymer layer attached to an anodizedaluminum foil layer;

FIG. 5A is a cross sectional diagram showing a surface embossed card ofthe type shown in FIG. 5;

FIG. 6 is a top view of a card having four colored layers to form a cardin accordance with the invention:

FIG. 6A is a cross sectional diagram of the card shown in FIG. 6;

FIG. 6B is a cross sectional diagram illustrating that an anodizedaluminum layer 14 may be formed having multi-colored levels;

FIG. 7 is a cross sectional diagram illustrating in FIGS. 7A through 7Esome of the process steps to form a metal card with a natural woodveneer in accordance with the invention;

FIG. 8 is a cross sectional diagram illustrating in FIGS. 8A through 8Dsome of the process steps to form a metal card with a cement veneer inaccordance with the invention;

FIG. 9 is a cross sectional diagram illustrating in FIGS. 9A through 9Esome of the process steps to form a metal card with a natural leatherveneer in accordance with the invention;

FIG. 10A is a top view of a pocket formed in the top surface of a metalsubstrate; FIG. 10B is a cross sectional diagram showing a decorativelayer attached to the pocket of FIG. 10A;

FIG. 10C is cross sectional diagram showing additional layers attachedto the bottom surface of the metal substrate;

FIG. 10D is a top isometric view of a metal substrate in which a pocketis formed to position therein a decorative layer which may be, forexample, an anodized metal layer or any veneer layers shown, forexample, in FIGS. 7A, 8A or 9A;

FIG. 10E is a top isometric view of the card of FIG. 10D with adecorative layer inserted in the pocket and attached to the metalsubstrate;

FIG. 11 is a highly simplified cross sectional diagram showingdecorative layers attached to the top and bottom surfaces of a metalsubstrate;

FIG. 11A through 11C are cross sectional diagrams showing that thedecorative layers attached to the top and bottom surfaces of a metalsubstrate may be different;

FIG. 11D is a cross sectional diagram showing ceramic and decorativelayers attached to the top and bottom surfaces of a metal substrate;

FIG. 11E is a cross-sectional diagram of a metal card with a ceramicdecorative layer to which a laser source is applied for modifying theappearance and texture of the card;

FIG. 11F is a cross sectional diagram showing one type of thindecorative layer (anodized aluminum) attached to the top and bottomsurfaces of a metal substrate in accordance with the invention;

FIG. 12 is a cross section diagram of a card with an optional polymerlayer attached to the bottom side of a decorative layer;

FIGS. 12A and 12B are bottom views of a signature panel and a magneticstripe attached to the underside of a polymer layer or an anodizedaluminum foil;

FIG. 13A is a cross sectional diagram of a card with a colored anodizedaluminum foil attached to a metal substrate in accordance with theinvention;

FIG. 13B is a diagram illustrating some of the process steps to form thecard in accordance with the invention.

FIG. 13C is a cross sectional diagram illustrating the formation of apattern in the anodized aluminum layer of FIG. 13A;

FIG. 13D is a cross sectional diagram illustrating the result ofelectroplating the pattern formed in the anodized aluminum layer of FIG.13A with a noble metal;

FIG. 14 is a cross sectional diagram of a card with a ceramic core anddecorative layers;

FIG. 14A is an isometric top view of a pocket formed in a ceramic corelayer; and

FIG. 14B is an isometric top view of a decorative layer attached to thepocket of FIG. 14A.

DETAILED DESCRIPTION OF THE INVENTION

Metal Cards with at Least One Anodized Layer

FIG. 1 shows one embodiment of a metal based transactional card 10having a number of different colored layers. In FIG. 1, card 10 includesa colorized hard-coat top layer 12 overlying an anodized aluminum foillayer 14. The hard coat layer 12 may be attached to the anodized layer14 by any known or suitable manner (e.g., by being bonded, sprayed onand cured, attached via an adhesive or carrier layer, or transferredfrom a carrier sheet). Layer 14 is attached via an adhesive layer 15 toa base metal layer 16. Layers 12 and 14 are designed to have selectedcolors which are used to provide the card 10 with a different coloredand decorative appearance. The color of layers 12 and 14 may be combinedwith the color of the base metal layer 16 to provide the card with astill greater range of colors and decorative patterns.

In the manufacture of the cards, the thickness of hard coat layer 12will typically be 2 to 50 microns, the thickness of aluminum foil layer14 may be in the range of 0.0005 inches to 0.014 inches, and thethickness of metal layer 16 may be in the range of 0.005 inches to 0.032inches. Note that layer 12 is optional and that layer 14 is primarilyintended to provide a decorative (coloring) function.

Layer 12 provides a scratch resistance surface and can also provide acolored layer. The hard coat layer 12 may be formed of nano-particles,such as silicate nanoparticles, zinc oxide nanoparticles, silicondioxide crystalline nano-particles, or any other suitable nano-particleswith a suitable carrier such as a solvent, water based, or UV curableacrylates, vinyls, urethane or the like. The hard coat can be applied bycoating techniques such as spraying, gravure, reverse roll, direct roll,or slot coating.

The hard coat layer 12 may be applied to a card, or to a subassemblyused in forming a card, by means of a special carrier layer. The specialcarrier enables a release layer and a hard coat layer to be attached tothe special carrier layer to form a subassembly which can then beattached and transferred to another subassembly to form an intermediateassembly from which the carrier and release layers can be removed,leaving the hard coat layer as the top and/or bottom layer of the card.The hard coat layer may be clear or colored. Color is added to the hardcoat layer by adding pigments or dyes to either the adhesive layer ormixed with the hard coat vehicle itself

The second layer 14 is comprised of a colored anodic metal layer whichis shown to be attached via an adhesive layer 15 to a base metal layer16. The layer 14 could also be bonded and laminated to the underlyinglayer 16. The anodized metal layer 14 is shown to be of aluminum.However, the anodized layer 14 may be titanium, zinc, niobium, tantalumor any other metal which can be anodized. In accordance with theinvention, an anodized layer may by further modified by: (a) dying theanodized layer a single color or multiple colors, or (b) by printedgraphics through techniques such as screen printing, sublimationprinting, or any digital print system. The anodized metal layer 14 maybe further modified through techniques such as laser engraving,mechanical engraving, die cutting, or embossing. The anodized metallayer may be used on the card as a full faced material (i.e., extendingthe full length and width of the card), as a patch, a stripe, or otherdecorative design.

Using a colorized anodic layer 14, instead of a polymer layer, upon acolored metal layer 16 provides more flexibility and cost savings. Useof printed anodic material to replace polymeric materials overcomes thechallenges present when using polymers since the metal is denser thanthe polymer and does not have the minimum print thickness limitations.This composition and method may be used on all transaction and ID cardtypes including contactless, contact, and dual interface smart cards.

The base or substrate metal layer 16 used in cards embodying theinvention may be any suitable metal, such as stainless steel, bronze,copper, titanium, or any alloy which gives the card most of its body(structure) and weight.

The layers 12, 14, 15, and 16 may be combined in one or more laminationsteps using heat, pressure, and/or UV curing. FIGS. 1, 1A and 1Billustrate the construction of a multi layered metal transaction cardwhere essentially the entire body of the card is metal and whose colorcan be controlled. A signature panel and a magnetic stripe (not shown)could be attached (directly or indirectly via a polymer layer) to theunderside of metal layer 15 shown in FIGS. 1, 1A and 1B to form acomplete transaction card.

In FIGS. 1, 1A and 1B there is shown a laser 101 for applying a laserbeam to a card 10. The power level of the laser 10 is controlled by apower controller 103. Controlling the power level of the laser enablesthe manufacture of cards whose colors can be varied and controlled. Thelaser can be used to ablate selected portions of the hard coat layer 12and of the anodized layer 14. In addition, the laser can be used tochange the color of the base metal layer 16 by controlling (varying) thepower level and polarization of the laser (e.g., this may be termed atype of diffraction lasering). In this manner the color and texture ofeach card may be controlled and varied.

FIG. 1A illustrates that a desirable color contrast may be created byselectively laser ablating or engraving the top layer 12, allowing the2^(nd) layer 14 to show through. This can be achieved with discrete,optimized laser parameters or engraving techniques.

FIG. 1B illustrates that a second set of parameters may be used toremove selected portions of the anodic layer 14, showing the base metal16 underneath. This allows for a multi-color gradient on the metal card,which may include the base metal finish itself. This aesthetic look ishighly desirable in the marketplace.

Note that only a single anodized layer is shown in the drawings.However, more than one (i.e., multiple) anodized suitable metal layerscould be used. For example, since there is one anodized layer per pieceof Aluminum, multiple aluminum layers could be included.

Hybrid Metal—Polymer Cards

FIG. 2 is a cross sectional diagram of a card 10 which includes thecoloring layers shown in FIG. 1 and, in addition, includes a polymericlayer 18 which is attached to the underside of metal layer 16 byadhesive layer 17. The assembly comprised of layers 12, 14, 15, 16, 17and 18 can be laminated to produce a “Hybrid” card comprising acombination of metal layers and at least one polymer layer. The polymerlayer 18 may be of any suitable material (e.g., PVC, PC, PET, etc . . .). The polymer layer 18 may include a magnetic stripe and a signaturepanel. Alternatively, a magnetic stripe and a signature panel may addedsubsequently after the cards have been separated from the sheet on whichmulti cards are being formed.

Wireless, Contact or Dual Interface Cards

FIG. 3 is a cross sectional diagram of a Hybrid dual interface metallicsmart card having coloring layers embodying the invention and FIG. 4 isan exploded view of the layers and components of a card of the typeshown in FIG. 3 (except that the adhesive layers have been omitted).FIGS. 3 and 4 illustrate that cards of selected texture and coloringembodying the invention may be made to include all the components neededto make each card a “smart” card. As shown in FIGS. 3 and 4, the “smart”cards are made to include an integrated circuit module 109 whichincludes an integrated circuit (IC) 110 (a semiconductor processor chipor micro chip) and a module antenna 112 for RF (wireless/contactless)transmission. The module 109 and its IC 110 are designed to interfacewith a reader (not shown). The module 109 and its IC 110 may alsoinclude contacts (116, 118) extending to the periphery of the card andalong the surface of the card to make contact with a reader. The module109 and its IC 110 may be used as part of a contactless (wireless)system and/or as a direct contact system and/or as a dual interface(contact and/or contactless) system. In FIG. 3, the card 10 includes aferrite layer 20 attached via adhesive layer 19 to the underside of themetal layer 16. A booster antenna formed on, or in, layer 22 is locatedbetween the ferrite layer 20 and the polymer layer 18. The ferrite layer20 is introduced to prevent the metal layer 16 from attenuating incomingand outgoing RF signals thereby enabling RF transmission between a cardreader (not shown) and the chip 110. There is a cut out through the toplayers of the card for the module 109 to fit through. The polymer layer18 may include a magnetic stripe and a signature panel or an additionallayer 24 may be attached to layer 18 to provide these functions. Withthe addition of a colored hard coat layer 12 and the anodized metallayer 14, “smart” dual interface metallic-hybrid cards formed as shownin FIGS. 3 and 4 can be made to have desired color and texturecharacteristics and also function as any regular smart hybrid or metalcard.

FIGS. 5 and 5A are cross sectional diagrams of a card like the one shownin FIG. 2 but which, in addition, also includes an embossable copolymerlayer 24 (identified in the Figs. as a polyester layer) formed on top ofthe anodized aluminum film layer 14. A card 10 may be formed as shown inFIG. 5 by assembling the layers 12, 24, 14, 16 and 18 and attaching thelayers by means of bonding and/or using adhesive layers 15, 17, 23. Theassembly can then be laminated and embossed by means of embossing andlaminating plates 55 a, 55 b to produce an embossed image on the toplayer as shown in FIG. 5A or in the other top layers 24 and 14 (layer 12is optional and may not be used on all cards). FIGS. 5 and 5A thusillustrate how the coloring and texture of cards can be controlled andmodified by embossing.

Alternatively, the embossable layer 24 may be a curable polymer and anadhesive layer subsequently attached. The hard coat layer 12 may beplaced on the embossable layer before or after the embossing step.During lamination, the embossing plate 55 a can be used to emboss adesired image into the co-polyester layer 24 (layer 24 can be anyembossable polymer) and also to emboss the anodized metal layer 14 belowit. The co-polyester layer 24 (as well as the hard coat layer) providesa scratch resistant layer and the embossing provides a tactile componentdesirable to the industry. That is, the embossed surface can provide atextured feel to the card. The hard coat layer 12 provides additionalprotection on top of the polyester and its carrier provides a releasefrom the embossing plate.

FIG. 6 is a top view and FIG. 6A is a cross sectional diagram of a metaltransaction card with which can display four (4) different colors and avariety of graphical and textural features. By way of example, the toplayer 12 may be a black colored hard coat layer which can provide abackground that is more scratch resistant and less expensive than PVD. Asecond layer 14 of anodized aluminum attached to layer 12 may be coloredpink. A third metal layer 16 attached to layer 14 is colored gray. Afourth layer 161, typically of thin plastic (but which may also be ametal layer), attached to layer 16 is colored silver. A laser source 101can be used to produce a textured and a controlled colored card. A firstset of laser settings removes selected portion of the hard coat layer 12revealing the anodized layer beneath. This is pink in the example andmay be used for text or graphics. A second laser setting removesportions of the pink anodized aluminum layer 14 to produce gray featuresof the metal layer 16. A third laser setting removes portions of thegray metal layer to produce silver colored features of layer 161.Intermediate gradients may be produced by partially removing each layer.This opens up a variety of artistic and textural possibilities on metaltransaction cards not previously possible.

FIG. 6B illustrates that the anodized layer 14 can be formed to containmany different colored sub-layers (141, 142, 143, 144). That is, layer14 is a multi-colored layer. During the anodizing process, differentcolors may be introduced to different sub-segments (sub-layers) of thealuminum layer. The different colors may be displayed by lasering downthrough the different sub-layers of layer 14 to display the differentcolored levels. Instead of lasering, the different colors may bedisplayed by mechanical engraving or other means of material removal.The additional layers may also be colorized hard coat layers solely orin combination with metal layers.

As discussed above, cards embodying the invention may be formed as shownin FIGS. 1, 2, 3, 5 and 6 by first assembling selected polymeric andmetals layers and bonding or adhesively attaching them. The variouslayers are generally laminated at temperatures ranging from 200 F to 500F under effective pressures of 50 to 500 PSIA. Typically, a first set ofoptimized laser or mechanical engraving parameters are used to removethe colored, transfer hard coat (e.g., 12) showing the colored, anodizedlayer beneath. Then, a second set of optimized laser or mechanicalengraving parameters are used to remove portions of the coloredanodizing layer (14), revealing the metal beneath. In the case of FIGS.6 and 6A a third set of optimized laser or mechanical engravingparameters may be used to reveal another colored layer (161). Thevarious layers may be further mechanically engraved through the anodizedmetal to the main body of the card, typically stainless steel. As afinal step in making the cards, cards are cut to size and finalprocessing such as hot stamp is completed.

The anodized aluminum layer is thus used as a thin decorative layer (seeDLa, DLb in FIG. 11). In accordance with one aspect of the invention, athin decorative layer includes at least one anodized metal layer to addcolor and/or texture to a card. The cards may also include additionallayers of different colors which may be assembled and laminated with theanodized metal layer to form multi layered cards. The cards may beprocessed (e.g., by lasering) to produce cards having different colorsand texture. A controlled varying laser power device (or any likefunctional device) may be applied to multi layered cards to removeselected portions of the different layers to alter the color and patternbeing displayed and the texture of the card.

In the manufacture of cards embodying the invention it has becomeimportant for commercial and aesthetic reasons to produce metal cardswith certain texture and color and to maintain the texture and color. Asalready discussed and shown above, metal cards embodying the inventionmay be formed to include a core metal layer 16 with a decorative layer(e.g., 14, or DLa in FIG. 11) above the metal layer 16. Alternatively, adecorative layer (e.g., DLa, DLb in FIG. 11) may be formed above andbelow the core metal layer 16, or only below the core metal layer.

Cards with Wood Veneer

FIG. 7 illustrates the manufacture of a “textured” metal card having athin decorative layer which is selected to be an actual wood layerpositioned on the top surface of the card. Note that the use of “wood”is by way of example only and is meant to include any material derivedfrom a (living) plant having similar characteristics to wood. The use ofa wood layer (or any like material) is aesthetically significant sinceit has unique properties. That is, the grain and appearance of an actualwood strip is virtually impossible to duplicate and represents a highlevel of individuality. However, significant problems exist inmaintaining the texture and appearance of the actual wood layer used informing cards. These are overcome in the manufacture of cards inaccordance with the invention.

Referring to FIG. 7, the following procedure or steps may be used:

-   -   1- As shown in FIG. 7A, a natural wood veneer layer 700 with low        lignin content is selected. The use of a wood layer with low        lignin content makes it easier to maintain the appearance of the        wood layer through the various lamination and processing steps        to form a card.    -   2- Pretreat the wood layer 700 having a top surface 701 and a        bottom surface 703, as shown in FIG. 7B:        -   a- Sand down back surface 703 of wood layer 700 until wood            layer has desired thickness. The range of the wood veneer            and all the other veneers may range from 0.001 inches to            0.014 inches.        -   b- Apply an oil film 711, such as linseed oil, to top            surface 701 of wood layer 700; the oil layer 711 ensures            that the moisture contained in the wood layer and its            general appearance is maintained when the wood undergoes            lamination. It was found that applying a thin oil film            (e.g., of linseed oil) was very significant in maintaining            the wood layer in good condition through the lamination            process. The oil replaces the water in the wood structure            with higher boiling point materials.    -   3- Form an assembly 750, as shown in FIG. 7C, which includes the        treated wood layer 700 attached to a metal substrate 16 with an        adhesive 15 a. The adhesive layer 15 a may include an acid        modified polyolefin or may be any suitable adhesive. Typically,        layer 700 will have a thickness ranging between 0.001 inches        0.014 inches and metal layer 16 will have a thickness ranging        between of 0.005 inches and 0.032 inches.    -   4- Laminate the assembly 750 as shown in FIG. 7D using platens        75 a and 75 b.    -   5- Note that platens 75 a and/or 75 b could also include        embossing plates (not shown) to enable the assembly 750 to be        embossed and laminated at the same time.    -   6- Chamfer the wood layer 700 as shown in FIG. 7E so as to cut        away (a right-angled edge or corner) to make a symmetrical        sloping edge and minimizes problems of the edges of the card        fraying or peeling back.        Cards with Cement Veneer

FIG. 8 illustrates the manufacture of a “textured” metal card having athin decorative layer which is selected to be a veneer layer 800 of anaggregate binder material. The aggregate binder material may be, forexample, cement, mortar, epoxies and glues, mixed with laser reactivematerials such as finely divided carbon or commercially available laseradditives, In FIG. 8A, the layer 800 is shown to be a cement layer mixedwith carbon material. But, as noted above, the cement may be another ofthe materials mentioned. The use of a cement layer provides a uniquetactile feel. However, significant problems exist in producing cardshaving certain texture and color and in maintaining the texture andproviding images with high level of contrast. These are overcome in themanufacture of these cards in accordance with the invention.

Referring to FIG. 8, the following procedure or steps may be used totreat an aggregate binder material (e.g., cement) and enhancing colorcontrast of the treated cards.

-   -   1- A shown in FIG. 8A, form a cement layer 800 from a cement mix        in which carbon material (e.g., carbon soot) has been added to        produce a grayish colored cement layer 800.    -   2- Grind down top and or bottom surfaces (801, 803) of layer 800        to produce a layer with desired thickness which typically ranges        between 0.001 inches and 0.010 inches.    -   3- Use laser apparatus 101 to laser the cement layer as shown in        FIG. 8B to produce a desired pattern (regions 804). The laser        101 vaporizes the carbon particles in selected regions producing        a white pattern which contrasts to the gray background.    -   4- The lasered cement layer 800 may then be attached to a metal        substrate 16 via a suitable adhesive layer 15 b to form assembly        850 as shown in FIG. 8C.    -   5- Alternatively to step 3 above, the unlasered cement layer 800        may first be attached to the metal substrate 16 and then        lasered.    -   6- FIG. 8D illustrates that a layer 800 a can be formed using an        epoxy material mixed with carbon particles. The layer 800 a can        be directly attached to a metal substrate 16. The layer 800 a        can be subjected to a lasering procedure before it is attached        to metal base 16 or after it is so attached. The use of an epoxy        material eliminates the need for an additional adhesive layer        and provides a very strong bond between the epoxy layer 800 a        and the underlying metal substrate 16, which may for example be        steel or any other suitable metal.        Cards with Leather Veneer

FIG. 9 illustrates the manufacture of a “textured” metal card having athin decorative layer which is selected to be an actual leather veneerlayer positioned on the top surface of the card. Note that any likeanimal derive material may be used instead. As in the case of the“natural” or “actual” wood layer, the use of an actual leather layer issignificant since it has many unique properties. That is, the grain andrichness of appearance and the pattern displayed by an actual leatherlayer is virtually impossible to duplicate and represents a high levelof personalization. However, significant problems exist in maintainingthe texture and appearance of the “natural” leather layer used informing cards. These are overcome in the manufacture of cards inaccordance with the invention.

-   -   Referring to FIG. 9, the following procedure or steps may be        used to form a card:    -   1. As shown in FIG. 9A, there is a selecting step. That is,        select a natural leather layer 900 having a natural unique        pattern on its top surface 901.    -   2. Then there is a leather processing or treatment for preparing        the backside 903 of the leather layer 900 so the leather layer        has the desirable thickness and the bottom surface is adapted to        accept an adhesive. A typical thickness will be in the range of        0.003 to 0.014 inches. Though this can be made thinner and        thicker.    -   3. Then there is an embossing step as s shown in FIG. 9B. A        desired pattern is embossed on the top surface 901 of first        (1^(st)) leather layer 900.    -   4. A highly novel feature employed to laminate the leather layer        900 to an underlying metal substrate 16 also enables the        production of a mirror image of the embossed pattern. Of great        significance is that the lamination procedure for securing the        embossed leather layer 900 to the underlying metal substrate 16        preserves all the fine features of the leather 900 layers as        well as the embossed pattern. This is accomplished as follows.        An assembly 910 is formed as shown in FIG. 9C which includes:        -   a- The embossed 1^(st) leather layer 900 attached via an            adhesive layer 15 c to a metal substrate layer 16; and        -   b- A blank (un-embossed) leather layer 902 (i.e., 2^(nd)            leather layer) having its top surface facing the embossed            surface 901 of 1^(st) leather layer 900 is shown placed            between the embossed leather layer 900 and a platen 75 a.            Layer 902 may be like layer 900 or may be any similar            leather like material. Layer 902 is selected to have the            same or similar texture to layer 900.    -   5. As shown in FIG. 9D, the assembly 910 undergoes a lamination        step. Due to the proper selection of layers 900 and 902 (and        appropriate lamination pressures), the lamination process        maintains the features and pattern embossed in 1^(st) leather        layer 900 intact to produce an assembly or sub assembly 950, as        shown in FIG. 9E.    -   6. At the same time the embossed pattern is transferred (as a        mirror image) to the top surface 911 of 2^(nd) leather layer 902        which can then be used to emboss a subsequent leather layer, or        like layer as shown in FIG. 9E. This is significant in that the        “unembossed” leather layers (e.g., 902) becomes the template for        the manufacture of a next series of cards; thereby producing        continuous generation.        Cards with Pocket for Decorative Layers/Patches

The edges of the veneer layers may be subjected to fraying and topeeling. One approach to avoid this problem is to chamfer the edges ofthe veneer layers as shown in FIG. 7E. Another approach is to form apocket 981 in the top surface of metal cards as shown in FIG. 10. FIG.10A is a top view of a card with a cut out 981 to form a pocket in thetop surface of the card. The pocket may be formed using any knowntechnique. The edges d1 and d2 may be in the range of 0.01 to 1.125inches and may be uneven or form an artistic pattern. FIG. 10B is across sectional view showing that an anodized aluminum layer 14 or anyveneer layer (e.g., 700, 800, 900) may be attached via a suitableadhesive 15 c to the top inside surface of the card's pocket 981 cut outfrom core metal layer 16. This arrangement is elegant and protects theedges of the anodized or veneer layers from being frayed, worn, orpeeling.

FIG. 10C illustrates that a polymer, aluminum or ceramic layer may beattached to the underside of the metal substrate.

FIG. 10D is an isometric top view of metal layer 16 in which the pocket981 has been formed. For purpose of illustration the pocket is shown notto be symmetrically located. The pocket 981 may be made a small or largeportion of the card surface with regular or irregular borders. FIG. 10Eillustrates that any decorative layer (DL) may be attached to, or formedwithin, the pocket 981. This includes anodized aluminum layers, variousveneer layers discussed above as well as any other decorative veneerlayers or substance. This includes, by way of example, a presentlycommercially available product termed Swarovski Elements Crystal Fabric.This material includes a carrier material that is completely covered bymillions of tiny cut and round crystals. It is elastic, tear resistantand extremely light. The carrier material features low temperature glueso that is may be applied to a variety of surfaces by low temperatureheating. This glue may be replaced with a more aggressive adhesive forharsher environments.

In other embodiments of the invention, small pockets of very limitedarea (e.g., a small portion of the surface area of the card) havingvirtually any shape can be formed in the card for the inclusion thereinof any decorative material.

The above is by way of illustration. In general. in accordance with theinvention various methods and apparatus have been shown for treating athin anodized metal layer and/or a selected thin veneer layers forattachment to a thick metal substrate for producing cards having desiredcolor and texture characteristics.

-   -   Metal cards embodying the invention may be formed as shown in        FIG. 11 to include a core metal layer 16 with a decorative layer        (DLa) above the metal layer and a decorative layer (DLb) below        the metal layer. Each one of the decorative layers DLa and DLb        may be: (a) an anodized metal layer, (b) a plant derived        material veneer layer, such as wood; (c) an animal derived        material veneer layer, such as leather; (d) an aggregate binder        material veneer layer, such as cement or epoxy mixed with laser        reactive materials; (e) a ceramic layer; or (f) a layer of        crystal fabric material. That is, one decorative layer (e.g.,        DLa) may be any one of the layers identified in a-f, above, and        the other decorative layer (e.g., DLb) may be like DLa or a        different one of the layers identified in a-f.

In FIG. 11A a leather layer 900 is attached via an adhesive 15 c to oneside (top surface in the figure) of the metal substrate 16 and ananodized aluminum layer 14 is attached to the other side (bottom surfacein the figure) of the metal substrate. In this figure (and in FIGS. 11Band 11C below) one type of thin decorative layer (e.g., leather) isattached to the top of a metal substrate and a different thin decorativelayer (e.g., anodized aluminum) is attached to the bottom surface of themetal substrate.

In FIG. 11B a leather layer 900 is attached via an adhesive 15 c to oneside (top surface) of the metal substrate 16 and a ceramic veneer layer990 is attached to the other side (bottom surface) of the metalsubstrate.

In FIG. 11C an anodized aluminum foil 14 a is attached via an adhesive15 to one side (top surface) of the metal substrate 16 and a ceramicveneer layer 990 is attached to the other side (bottom surface) of themetal substrate. A signature panel 123 and a magnetic stripe 125 areshown attached to the ceramic layer 990.

-   -   FIGS. 11B and 11C illustrate that a decorative veneer layer may        be a layer of ceramic material 990. Ceramic materials have very        desirable characteristics because they may be made to have        virtually any color and can be attached (bonded) to the metal        substrate without using an adhesive. The layer of ceramic        material may be applied directly (e.g., sprayed on) to the metal        substrate 16 and then baked on or cured to the metal 16. In        addition, FIGS. 11B and 11C illustrate that one of the        decorative layers may be a veneer layer of one type (leather,        anodized aluminum) and the other decorative layer may be of a        different type( e.g., ceramic).    -   FIG. 11D illustrates that a metal substrate 16 may have a        decorative layer DLa and a ceramic layer 990 a attached to tis        top surface and a decorative layer DLb and a ceramic layer 990 b        attached to its bottom surface. Due to the wide range of        different color and textures available to the decorative layers        and the ceramic layers, cards may be made with a very wide range        of coloring and textures.    -   FIG. 11E shows a laser source 101 which can be used to laser        engrave a decorative ceramic layer 990 a attached to the top        surface of a metal substrate 16 having a like or different        decorative layer DLb attached to the bottom surface of layer 16.        the ceramic layer 990 a also may be modified with mechanical or        chemical engraving, inkjet printing, laser marking and other        methods known to the art to provide a desired artistic effect.    -   FIG. 11F shows a metal substrate 16 with an anodized aluminum        foil 14 a attached to its top surface and an anodized aluminum        foil 14 b attached to its bottom surface. Foils 14 a and 14 b        may have different colors, thicknesses and shapes.    -   FIG. 12 is a cross sectional diagram of a metal card showing a        structure similar to that of FIG. 11F. The card has an anodized        aluminum layer 14 a attached via an adhesive 15 to one side (top        surface in the figure) of a metal substrate 16 and another        anodized aluminum layer 14 b attached via an adhesive 17 to the        other side (bottom surface in the figure) of the metal        substrate. Anodized layers 14 a and 14 b are decorative layers        attached to the metal layer 16. A polymer layer 121 is shown        attached to the bottom side of layer 14 b. As shown in FIG. 12A,        layer 121 may be a clear polymer layer so that the coloring and        decorative features of layer 14 b can be displayed and seen. A        signature panel 123 and a magnetic stripe 125 are formed on the        surface of layer 121.    -   The use of Layer 121 is optional. As shown in FIG. 12B, the        bottom layer of the card may be layer 14 b (i.e., no polymer        layer is used). In a particular embodiment, Applicants used a        thermoset type adhesive to attach a signature panel 123 and a        mag stripe 125 directly to the anodized aluminum layer 14 b.    -   FIG. 13A illustrates the coloring and decorative features of        cards embodying the invention. In FIG. 13A, the top anodized        layer 14 a has a top region 141 which, by way of example, is        colored blue. The thickness of region 141 may range from less        than 0.1 microns to more than 5 microns. (However it should be        understood that it is subject to a wide variation). Layer 14 a        is attached via adhesive layer 15 to the core metal substrate 16        which in turn is attached via an adhesive 17 to a decorative        layer DLb which may be any layer of the type identified as (a)        through (f), above.

As shown in FIG. 13B, after the layers shown in FIG. 13A are assembled(see box 1041), a pattern may be formed by removing selected portions ofthe anodic material in region 141 (see box 1042), leaving the underlyinguncolored aluminum foil. That is, the portion of layer 14 or 14 a belowregion 141. The removal of material in region 141 may be done by meansof a laser or by any other suitable means. For example, if a laser isused, the laser just removes material in layer 141 until it gets pastregion 141, baring the rest of layer 141. This is illustrated in FIG.13C, which shows the pattern limited to removal of selected portions ofthe blue colored material in region 141, The lasered assembly can thenbe subjected to an electroplating process (see box 1043), with a metalsuch as gold or any suitable metal, for electroplating the selectedmetal on or within the pattern formed in the anodic region 141. Thepattern formed may have the appearance shown in FIG. 13D. The card maybe further processed (completed), as shown in box 1044, to include anyand all additional features to form all types of cards as discussedabove.

Ceramic Cards

-   -   FIG. 14 illustrates that a card 10 a can be formed with a        ceramic core 131 which can be designed to provide a        predetermined color. A decorative layer DLa can be attached to        the top side of the ceramic core and/or another decorative layer        DLb can be attached to the bottom side of the core layer. The        decorative layer DLa may be the same as the decorative layer        DLb; but they need not be the same. FIG. 14A illustrates that a        pocket 981 can be formed within the ceramic layer for the        placement therein of a decorative layer (DL) as shown in FIG.        14B. The decorative layer may be any layer of the type discussed        above or any other suitable material. The ceramic materials are        inorganic, non-metallic materials made from compounds of a metal        and a non-metal. Ceramic materials may be crystalline or partly        crystalline. They are formed by the action of heat and        subsequent cooling. Ceramic materials tend to be strong, stiff,        brittle, chemically inert, and non-conductors of heat and        electricity.

It is desirable to use ceramic cards for similar reasons that it isdesirable to use metal cards. In the modem transactional card market, itis often desirable to obtain a ‘premium’ feel, look, or tactile featurethat may be marketed to an affluent market. These transactional cardsmay be used as debit cards, credit cards, or pre-paid cards. As part ofthis premium feel, a card that is heavier than a standard plastic cardis often desired, as well as an increased durability of the card body.In order to achieve these desired effects, several card constructionsutilizing ceramic components are described herein, including exemplaryembodiments in the form of: a solid ceramic card, a card containingceramic inserts, and a card utilizing a ceramic coating.

A solid ceramic card may be created using injection molding to itsdesired shape followed by sintering to create nominal dimensions of astandard sized card: 3.37″×2.125″×0.03″ (although not limited to anyparticular size). Pockets may be created in the injection moldingprocess to allow insertion of functional features such as a magneticstripe, contact or dual interface chip module, a booster antenna fordual interface cards, holograms, signature panel or branding. Theceramic card body may also be created from larger blocks of ceramic andmachined to desired size. The ceramic part may also be 3D printed forproduction. In preferred embodiments, the ceramic may comprise asintered zirconia dioxide, but may also comprise one or more of thefollowing oxides, without limitation: alumina, beryllia, ceria,ceramide, carbide, boride, nitride or silicide.

A solid ceramic card provides functional advantages to existing premium,metal cards in that it does not have to be significantly machined, doesnot produce electrostatic discharge, and does not interfere with RFradiation for contactless transactions. Aesthetically, the solid ceramiccard may be obtained in a variety of colors by adding pigment to theceramic compound and may be further changed by laser marking, addingdesired features such as a laser signature or decorative design feature.Security elements such as through holes, windows, or microtext may alsobe added via laser, mechanical, or chemical engraving, or by any methodknown in the field.

As shown in FIGS. 11B, 11C 11D, and 11E, transaction cards comprisingmetal-ceramic composites containing metal and ceramic may also beprovided. In one embodiment, ceramic inserts may be placed into metaland metal-plastic cards to create unique features and increase theavailable color, texture, and laser features on the card whilemaintaining most of the weight of a metal card. For example, suchinserts may be attached by milling a pocket in the core, placing anadhesive in the pocket, and adhering the ceramic insert in the pocket.In another embodiment, the ceramic insert and a milled pocket mayrespectively be configured such that a press fit holds the ceramicinsert in place. In still another embodiment, the core may have one ormore tapped holes disposed in the edges thereof such that the coreserves as a frame, in which set screws disposed in the tapped holes holdthe ceramic insert within the frame. The attachment of ceramic insertsto a core, however, is not limited to any particular method.

Metal core cards, with dual and single sided ceramic coatings may alsobe provided (see FIGS. 11B, 11C, 11D and 11E). The metal core maycomprise a solid 0.024″ to 0.030″ (but not limited to any particularthickness) metal such as but not limited to metals comprising: brass,steel, nickel, palladium, silver, gold, platinum, aluminum or any othersuitable metal or metal alloy known to the art. The metal core may alsocomprise a composite construction, such as a core containing a firstmetal 0.001″-0.029″ thick (although not limited to any particularthickness) bonded to a second metal 0.001″-0.029″ thick (although notlimited to any particular thickness), or any plurality of layerscomposing a desired thickness of the card. This composite material maybe desired for a specific weight or color that may show when the ceramicis laser marked. Utilizing composite metals may also increase costefficiency. Metal-plastic composite cards with single and dual sidedceramic coatings may achieve desired manufacturing costs, weights, andartistic effects.

In one exemplary embodiment, a 0.02″ thick metal core (such as steel)may be bonded to a 0.007″ thick PVC layer on one side with a ceramiccoating on the un-bonded surface of the metal core. The ceramic may beapplied as a spray coating, which is then thermally, air, or UV cured.After curing, the coating is typically 0.001″-0.003″ thick, depending onthe desired look of the coating. These coatings may be produced in avariety of colors. Typically, the coating is composed of ceramicmicroparticles containing zirconia dioxide, aluminum disilicide, and acurable resin binder suspended in a volatile organic carrier solution,such as a CERAKOTE® ceramic coating, manufactured by or on behalf of NICIndustries, Inc. Once sprayed and cured, the coating provides a uniquecolor and texture to the cards along with an extremely durable finish,typically reaching several thousand Taber abrader cycles. The ceramiccoating may be modified with mechanical or chemical engraving, inkjetprinting, laser marking and other methods known to the art to provide adesired artistic effect, such as to include a design on the card, suchas is shown, for example, in FIG. 11E. A magnetic stripe, signaturepanel, branding, hologram and other functional features of thetransactional card may be applied directly to the ceramic surface (see123, 125, in FIG. 11C), or a pocket may be created (se FIG. 10C), suchas by mechanical or laser engraving, to allow such features to bond tothe metal core.

Thus, an exemplary method for producing an exemplary ceramic card with ametal core may comprise the following steps:

-   -   1. Provide metal core sheet. (Optional—Step of providing the        metal core may comprise laminating a metal foil, such as        aluminum foil, to one or more surfaces of an inner subcore, in        which the subcore may comprise any material, but typically metal        or plastic).    -   2. Add fixturing to metal core, such as adding fixturing holes        and fixtures used for holding the sheet in place while the next        steps are performed.    -   3. Create surface features, such as pockets. for example, for        holding a booster antenna for use in connection with an RFID        chip, which can be disposed below the ceramic layer. Also,        pockets in the core may be provided that ultimately result in        depressions in the ceramic coating into which later component s        (such as the RFID chip) can be attached at the end of        processing, to provide for a smooth surface in the final        product.    -   4. Apply surface finish to core (bead blasting, tumbling,        brushing, etc.)    -   5. Coat with ceramic on one or both sides.    -   6. Laser mark ceramic coated metal sheet with designs or other        surface features, and make any other mechanical, chemical, or        laser modifications needed to facilitate later attachment of        other components. For example, edges of any pockets or        depressions may be processed for a better fit of features to be        added in a subsequent step or areas where an adhesive is later        applied may be roughened for better adhesion.    -   7. Cut sheet into card blanks, such as using CNC (computer        numerical control) machine    -   8. Apply functional and security features (mag stripe, chip,        hologram, etc.) to individual card blanks. As noted above, such        features may fit in a pocket created earlier in the process or        adhesively attached to an area that has been roughened. The        magnetic stripe, however, is preferably applied directly on the        ceramic coating, because of the benefits of application onto a        surface that is as planar and flat as possible.

In the identification card market, which is traditionally composed ofcomposite plastics or polycarbonate, ceramics offers new possibilitiesto increase card lifespan and making the cards much more challenging tocounterfeit. Colored and clear ceramic coatings may be applied toplastic cores to create significantly more durable materials as testedby ISO standard flexibility and wear testing. Additionally, thesematerials are much harder to counterfeit and allow for unique lasermarking properties as well as inclusion of unique phosphors in theceramic which can shift incident light up or downfield, creating aunique light “watermark” as part of the ID.

1. A method for making a card with a given appearance comprising thesteps of: (a) preparing a decorative metal layer by anodizing a metallayer, then coloring the anodized metal layer with a dye to give theanodized metal layer a given color, and then sealing the colorizeddecorative metal layer; (b) preparing a core metal layer for forming thebody of said card, said core layer having first and second surfacesgenerally parallel to each other, and a core color that differs from thegiven color of the colorized decorative metal layer; (c) afterperforming each of steps (a) and (b), attaching said decorative metallayer to the metal core layer by laminating the layers; (d) forming ahard coat layer over said decorative metal layer having a color that isdifferent than the core layer and the decorative metal layer; (e)removing portions of the hard coat layer in a first area to expose thedecorative metal layer; and (f) removing portions of the hard coat layerand any intervening layers in a second area different from the firstarea to expose the core metal layer, (g) electroplating a third area ofthe decorative metal layer different from the first area and the secondarea with an electroplating metal having an electroplating color thatdiffers from the given color of the colorized decorative metal layer andthe core color of the core metal layer; such that after performing eachof steps (e) through (g), the card has a face displaying the color ofthe hard coat layer in a fourth area, the core color of the core metallayer in the second area, the electroplating color of the electroplatingin the third area, and the given color of the colorized decorative metallayer in the first area; and wherein said decorative metal layercomprises anodized aluminum.
 2. The method of claim 1, furthercomprising an embossable polymer layer attached to the decorative metallayer and further including the step of embossing said polymer layer andsaid decorative metal layer for modifying the feel of the card.
 3. Themethod of claim 1, further including the step of preparing a plantderived material veneer layer, wherein the plant derived material veneerlayer is a layer of natural wood of low lignin content and wherein theprocessing of said wood veneer layer includes: (a) sanding down the backsurface of the wood layer until the wood layer has a thickness rangingbetween 0.001 inches and 0.015 inches; and (b) applying an oil film tothe wood layer to maintain the appearance of the wood layer when itundergoes lamination.
 4. The method of claim 3, further including thestep of chamfering the outer edges of the wood layer to prevent frayingor peeling of the wood layer.
 5. The method of claim 1, furtherincluding the step of preparing an animal derived material veneer layer,wherein the animal derived material veneer layer is a layer of naturalleather having top and bottom surfaces and wherein the processing ofsaid leather veneer layer includes treating the bottom surface of theleather layer so the thickness of the leather layer ranges between 0.001and 0.015 inches and its bottom surface is adapted to accept anadhesive.
 6. The method of claim 5, further comprising the steps of:embossing the top surface of said leather layer; and forming a firstassembly comprised of said leather layer having its bottom surfaceattached to said first surface of said core metal layer.
 7. The methodof claim 6, wherein said embossed leather layer is a first leather layerand further including the steps of: forming a second assembly comprisingthe positioning of a second leather layer, having top and bottomsurfaces, with its top surface facing the top surface of the first,embossed, leather layer of said first assembly; and laminating the firstand second leather layers and the core metal layer whereby the embossedpattern of the first leather layer is transferred to the second leatherlayer and the components of the first assembly are laminated.
 8. Themethod of claim 1, further including the step of preparing an aggregatebinder material veneer layer, wherein the aggregate binder materialveneer layer is a layer of cement or epoxy mixed with laser reactivematerials; and further including the steps of applying a laser source tosaid cement or epoxy layer mixed with carbon particles to vaporize thecarbon particles and produce a pattern with high contrast.
 9. The methodof claim 1, wherein the decorative metal layer comprises a layer ofceramic material and further including the step of applying said ceramiclayer onto the core metal layer and bonding it to the core metal layer.10. The method of claim 1, wherein the step of (f) includes using alaser device to remove portions of the decorative metal layer, andwherein said electroplating metal is a noble metal such as gold.
 11. Acard having a front side and a back side, said card comprising: a coremetal layer forming the bulk of the card and having a predeterminedcolor and said core metal layer having first and second surfacesextending generally parallel to each other; a decorative metal layerdisposed over said first surface of said core metal layer for providingat least one of color and texture to the card, said decorative layercomprising a colorized anodized metal layer having a given colordifferent from the predetermined color of the core metal layer; a hardcoat layer attached to said decorative layer having a color that isdifferent than the core metal layer and the decorative layer; an openingformed through the hard coat layer for displaying the color of thedecorative layer; a second opening different from the opening formedthrough the hard coat layer and any intervening layers for displayingthe color of the core metal layer; an area of the decorative metal layerdifferent from the opening and the second opening for displaying anelectroplating color different from the color of the decorative layerand the color of the core metal layer; wherein the core metal layer andthe decorative layer are laminated together, and the colors of the hardcoat layer, the decorative layer, the electroplated area, and the coremetal layer are visible from the front side of the card; and the hardcoat layer is formed over said anodized metal layer and having adifferent color than said given color, and a pattern formed within saidhard coat layer and said anodized metal layer producing a patterndisplaying the colors of said hard coat layer, said anodized layer andsaid core metal layer.
 12. The card of claim 11, wherein the decorativemetal layer comprises aluminum.
 13. The card of claim 11, furtherincluding an embossable polymer layer attached to the anodized metallayer; and wherein a pattern is embossed within said polymer layer forproducing a corresponding pattern in the top surface, which can be felt.14. The card of claim 11, further including an animal derived materialveneer layer, wherein said animal derived material veneer layer is alayer of actual leather having top and bottom surfaces with the topsurface having a unique pattern associated with actual leather; saidleather veneer layer having a thickness which ranges between 0.001inches and 0.020 inches; the bottom surface of the leather layer treatedso it is adapted to accept an adhesive; and wherein the top surface ofthe leather layer is embossed and its bottom surface is attached via anadhesive layer to said core metal layer.
 15. The card of claim 11,further including an aggregate binder material veneer layer, aggregatebinder material veneer layer being a layer of cement or epoxy mixed withlaser reactive materials; and wherein a pattern is formed in saidaggregate binder material veneer layer due to vaporization of the carbonparticles.
 16. The card of claim 11, wherein the anodized metal layerhas a predetermined colored region extending to a given depth within thedecorative metal layer, and wherein selected portions of the coloredregion are removed to said given depth in accordance with a designpattern; and a particular metal having a color other than saidpredetermined colored region is electroplated within said removedselected regions for producing a pattern displaying the colors of saidparticular metal and said predetermined colored region.
 17. The card ofclaim 16, wherein said anodized metal layer is a layer of aluminumhaving a top sub layer region which is dyed to have said predeterminedcolor and wherein said particular metal is a noble metal such as gold.18. The card of claim 11, further comprising a ceramic layer attached tothe first surface of the core metal layer and a decorative layer, otherthan a ceramic layer, is attached to the ceramic layer.
 19. The card ofclaim 11, wherein a first ceramic layer is attached to the first surfaceof the core metal layer and a second ceramic layer is attached to thesecond surface of the core metal layer.
 20. The card of claim 11,wherein said the core metal layer comprises a ceramic layer.
 21. A metalcard comprising: a metal layer forming the bulk of the card and having apredetermined color; said metal layer having a top surface and a bottomsurface; a pocket formed within the top surface of the metal layer, thedepth of the pocket extending below the surface of the metal layer; anda border around the outer periphery of the metal layer; and a decorativelayer attached to the pocket formed within said top surface of the metallayer.
 22. The card of claim 21, wherein said decorative layer has athickness in the range of 0.005 inches to 0.030 inches; and wherein saiddecorative layer is one of: (a) an anodized metal layer, (b) a plantderived material veneer layer, such as wood; (c) an animal derivedmaterial veneer layer, such as leather; (d) an aggregate binder materialveneer layer, such as cement or epoxy mixed with laser reactivematerials; (e) a ceramic layer; and (f) a layer of crystal fabricmaterial.
 23. The card of claim 22, wherein said anodized metal layer isone of aluminum, titanium, zinc, niobium, tantalum or any other metalwhich can be anodized.
 24. The card of claim 21, wherein the decorativelayer is one of wood, leather, ceramic, crystal fabric material, cementor epoxy.
 25. A method of making a card comprising the steps of:preparing a metal layer having generally parallel top and bottomsurfaces; forming a pocket in the top surface of said metal layer; thedepth of the pocket extending below the surface of the metal layer and aborder around the outer periphery of the metal layer, and attaching adecorative layer to the pocket formed within said top surface of themetal layer for providing at least one of color and texture to the card.26. The method of claim 25, wherein wherein said decorative layer has athickness in the range of 0.003 inches to 0.030 inches; and wherein saiddecorative layer is one of: (a) an anodized metal layer, (b) a plantderived material veneer layer, such as wood; (c) an animal derivedmaterial veneer layer, such as leather; and (d) an aggregate bindermaterial veneer layer, such as cement or epoxy mixed with laser reactivematerials.
 27. A method of making cards including the steps of:selecting a layer of a first leather like material having top and bottomsurfaces; embossing a pattern on a said top surface of said firstleather like material; selecting a layer of a second leather likematerial having top and bottom surfaces; forming an assembly comprisingplacing the top surface of the second leather like layer onto the topsurface of the embossed first layer with said first layer overlying andattached to a metal substrate; and laminating the assembly so aslaminate the embossed first layer with said metal substrate for forminga card or a sub assembly of a card and concurrently also embossing thetop surface of the second leather like layer.
 28. A card having a frontside and a back side, said card comprising: a thick ceramic layer havinga thickness in the range of 0.005 inches to 0.032 inches; said thickceramic layer forming the bulk of the card and having a predeterminedcolor and said thick metal layer having first and second surfacesextending generally parallel to each other; and a thin decorative layerattached to said first surface of said thick ceramic layer for providingat least one of color and texture to the card; said thin decorativelayer having a thickness in the range of 0.0005 inches to 0.014 inches;said thin decorative layer being one of: (a) an anodized metal layer,(b) a plant derived material veneer layer, such as wood; (c) an animalderived material Veneer layer, such as leather, and (d) an aggregatebinder material veneer layer, such as cement or epoxy, mixed with laserreactive materials; (e) a ceramic layer; and (f) a layer of crystalfabric material.